Electrical interconnects for photovoltaic modules and methods thereof

ABSTRACT

System and method for interconnecting photovoltaic modules. The system includes a first photovoltaic module and a second photovoltaic module. The first photovoltaic module includes a first bus bar and a first interconnect tab connected to the first bus bar. The second photovoltaic module includes a second bus bar and a second interconnect tab connected to the second bus bar. The system for interconnecting photovoltaic modules additionally includes a module interconnector configured to interconnect the first and the second photovoltaic modules. The module interconnector includes an interconnection component and an interconnection protector. Additionally, the system for interconnecting photovoltaic modules includes a first connection component connecting the interconnection component to the first interconnect tab of the first photovoltaic module and a second connection component connecting the interconnection component to the second interconnect tab of the second photovoltaic module.

1. CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/370,369, filed Aug. 3, 2010, commonly assigned and incorporated byreference herein for all purposes.

2. BACKGROUND OF THE INVENTION

The present invention is directed to interconnects for photovoltaicmodules. More particularly, the invention provides electricalinterconnects between conductive tabs for photovoltaic modules andmethods thereof. Merely by way of example, the invention has beenapplied to the interconnection of photovoltaic modules withinterconnection protectors. But it would be recognized that theinvention has a much broader range of applicability.

A traditional photovoltaic module (“PV module) often is equipped in thefactory with two wires and expensive electrical connectors. For example,these expensive electrical connectors might include push-to-connectconnectors such as MC-4 compatible connectors. These conventional wiresand connectors are then used at the installation site to interconnect PVmodules into strings of modules or into larger photovoltaic arrays. Thephotovoltaic strings and modules are typically mounted in areas wherethey are exposed to extremes of heat and cold, are subject to thermalcycling, and are subject to hazardous weather conditions such as highwinds, rain, sleet, and/or snow. Consequently, the electrical connectorsinterconnecting the PV modules must be weatherproof for decades,tolerant of thermal cycling, and/or allow for rapid assembly.

To minimize the total cost of a photovoltaic installation, it is oftendesirable to reduce both the cost of the PV module and the laborrequired for installation. Although the PV modules need to beweatherproof after final installation at the installation site, therequirements for weatherproofing often are not as stringent betweenfabrication of the PV module in the factory and installation of the PVmodule at the installation site. In addition, for large installations,specialized and/or automated interconnection tooling may be used. Thus,improved interconnections between PV modules in a large photovoltaicarray can, for example, provide a significant reduction in material,labor, and/or construction costs. In another example, improvedinterconnections increases the packing density of PV modules reducingthe cost of shipping PV modules to the installation site.

Hence, it is highly desirable to improve techniques for interconnectingPV modules so to optimize the hardware and/or the process forelectrically interconnecting the PV modules to reduce the total cost ofthe photovoltaic installation.

3. BRIEF SUMMARY OF THE INVENTION

The present invention is directed to interconnects for photovoltaicmodules. More particularly, the invention provides electricalinterconnects between conductive tabs for photovoltaic modules andmethods thereof. Merely by way of example, the invention has beenapplied to the interconnection of photovoltaic modules withinterconnection protectors. But it would be recognized that theinvention has a much broader range of applicability.

According to one embodiment, a system for interconnecting photovoltaicmodules includes a first photovoltaic module and a second photovoltaicmodule. The first photovoltaic module includes a first bus bar and afirst interconnect tab connected to the first bus bar. The secondphotovoltaic module includes a second bus bar and a second interconnecttab connected to the second bus bar. The system for interconnectingphotovoltaic modules additionally includes a module interconnectorconfigured to interconnect the first photovoltaic module and the secondphotovoltaic module. The module interconnector includes aninterconnection component and an interconnection protector.Additionally, the system for interconnecting photovoltaic modulesincludes a first connection component connecting the interconnectioncomponent to the first interconnect tab of the first photovoltaic moduleand a second connection component connecting the interconnectioncomponent to the second interconnect tab of the second photovoltaicmodule. The interconnection protector substantially encloses theinterconnection component, the first connection component, and thesecond connection component.

According to another embodiment, a method for installing photovoltaicmodules includes providing a first photovoltaic module that includes afirst bus bar, providing a second photovoltaic module that includes asecond bus bar, attaching a first interconnect tab to the first bus bar,and attaching a second interconnect tab to the second bus bar. Themethod for installing photovoltaic modules further includesinterconnecting the first photovoltaic module and the secondphotovoltaic module by connecting the first interconnect tab to aninterconnection component with a first connection component and byconnecting the second interconnect tab to the interconnection componentwith a second connection component. The method for installingphotovoltaic modules additionally includes enclosing substantially theinterconnection component, the first connection component, and thesecond connection component by an interconnection protector. The methodfor installing photovoltaic modules additionally includes packing, forshipping, at least the first photovoltaic module and the secondphotovoltaic module, the first photovoltaic module and the secondphotovoltaic module being interconnected to each other, shipping, to aninstallation site, at least the packed first photovoltaic module andsecond photovoltaic module, the first photovoltaic module and the secondphotovoltaic module being interconnected to each other, and installing,at the installation site, at least the first photovoltaic module and thesecond photovoltaic module.

According to yet another embodiment, a method for installingphotovoltaic modules includes providing a first photovoltaic module thatincludes a first bus bar and a first interconnect tab connected to thefirst bus bar and providing a second photovoltaic module that includes asecond bus bar and a second interconnect tab connected to the second busbar. The method for installing photovoltaic modules further includescoating the first interconnect tab at least partially with a firstprotective film and coating the second interconnect tab at leastpartially with a second protective film. The method for installingphotovoltaic modules additionally includes packing, for shipping, atleast the first photovoltaic module and the second photovoltaic module,shipping, to an installation site, at least the packed firstphotovoltaic module and second photovoltaic module, and installing, atthe installation site, at least the first photovoltaic module and thesecond photovoltaic module. The method for installing photovoltaicmodules additionally includes interconnecting, at the installation site,the installed first photovoltaic module and the installed secondphotovoltaic module by connecting the first interconnect tab to aninterconnection component with a first connection component and byconnecting the second interconnect tab to the interconnection componentwith a second connection component. The method for installingphotovoltaic modules additionally includes enclosing substantially theinterconnection component, the first connection component, and thesecond connection component with an interconnection protector.

Depending upon the embodiment, one or more of these benefits may beachieved. These benefits and various additional objects, features, andadvantages of the present invention can be fully appreciated withreference to the detailed description and accompanying drawings thatfollow.

4. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified diagram showing a planar view of a photovoltaicmodule interconnection system according to one embodiment of the presentinvention.

FIG. 2 is a simplified diagram showing a side view of the photovoltaicmodule interconnection system according to one embodiment of the presentinvention.

FIG. 3 is a simplified diagram showing a planar view of a photovoltaicmodule as part of the photovoltaic module interconnection systemaccording to one embodiment of the present invention.

FIG. 4 is a simplified diagram showing a side view of a photovoltaicmodule as part of the photovoltaic module interconnection systemaccording to another embodiment of the present invention.

FIG. 5 is a simplified diagram showing a side view of a photovoltaicmodule as part of the photovoltaic module interconnection systemaccording to yet another embodiment of the present invention

FIG. 6 is a simplified diagram showing a side view of a photovoltaicmodule as part of the photovoltaic module interconnection systemaccording to yet another embodiment of the present invention.

FIG. 7 is a simplified diagram showing a method for installingphotovoltaic modules using the photovoltaic module interconnectionsystem according to one embodiment of the present invention.

FIG. 8 is a simplified diagram showing a method for installingphotovoltaic modules using the photovoltaic module interconnectionsystem according to another embodiment of the present invention.

5. DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to interconnects for photovoltaicmodules. More particularly, the invention provides electricalinterconnects between conductive tabs for photovoltaic modules andmethods thereof. Merely by way of example, the invention has beenapplied to the interconnection of photovoltaic modules withinterconnection protectors. But it would be recognized that theinvention has a much broader range of applicability.

FIG. 1 is a simplified diagram showing a planar view of a photovoltaicmodule interconnection system according to one embodiment of the presentinvention. This diagram is merely an example, which should not undulylimit the scope of the claims. One of ordinary skill in the art wouldrecognize many variations, alternatives, and modifications. In FIG. 1,the photovoltaic interconnection system 100 includes a plurality of PVmodules 51. In one example, the PV modules 51 are interconnected toneighboring PV modules 51 using an interconnection system. In anotherexample, each of the plurality of PV modules 51 includes a plurality ofbus bars 52 and/or a plurality of interconnect tabs 53. In yet anotherexample, a first PV module 51 and a second PV module 51 areinterconnected using a module interconnector 57.

FIG. 2 is a simplified diagram showing a side view of the photovoltaicmodule interconnection system 100 according to one embodiment of thepresent invention. This diagram is merely an example, which should notunduly limit the scope of the claims. One of ordinary skill in the artwould recognize many variations, alternatives, and modifications.

FIG. 3 is a simplified diagram showing a planar view of a photovoltaicmodule 51 as part of the photovoltaic module interconnection system 100according to one embodiment of the present invention. This diagram ismerely an example, which should not unduly limit the scope of theclaims. One of ordinary skill in the art would recognize manyvariations, alternatives, and modifications. In FIG. 3, the PV module 51includes a plurality of bus bars 32. In one example, the plurality ofbus bars 32 are the plurality of bus bars 52. In another example, eachPV module 51 includes two bus bars 32 coupled to the positive andnegative ends of the array of photovoltaic cells included in the PVmodule 51.

In some embodiments, the PV module includes a plurality of interconnecttabs 33 that extend beyond the edge of the PV module 51 and protrudefrom a side of the PV module 51. In other embodiments, the plurality ofinterconnect tabs 33 are the plurality of interconnect tabs 53. In yetanother embodiment, the each of the plurality of interconnect tabs 33 isan extension of the respective bus bar 32. In yet another embodiment,each of the plurality of interconnect tabs 33 is an additionalconductor. In yet another embodiment, the plurality of interconnect tabs33 are not rated to be weatherproof as assembled in the factory, but arepotted (e.g., cemented) in a weatherproof package at the installationsite. In yet another embodiment, each of the plurality of interconnecttabs 33 is coated at least partially with an electrically protectivefilm.

FIG. 4 is a simplified diagram showing a side view of a photovoltaicmodule 51 as part of the photovoltaic module interconnection system 100according to another embodiment of the present invention. This diagramis merely an example, which should not unduly limit the scope of theclaims. One of ordinary skill in the art would recognize manyvariations, alternatives, and modifications. As shown in FIG. 4, the PVmodule 51 includes a photovoltaic panel 12 that includes active andconductive layers. For example, the photovoltaic panel 12 includes anymaterial such as silicon, cadmium telluride, CIGS, organics, and/orother photovoltaic active materials. In another example, thephotovoltaic module 51 includes a plurality of interconnect tabs 13. Inyet another example, the plurality of interconnect tabs 13 are theplurality of interconnect tabs 33 and/or the plurality of interconnecttabs 53. In yet another example, each of the plurality of interconnecttabs 13 is an extension of a respective bus bar connected to thephotovoltaic panel 12. In yet another example, each of the plurality ofinterconnect tabs 13 is a separate conductor from the respective busbar. In yet another example, each of the plurality of interconnect tabs13 is coated at least partially with an electrically protective film.

In one embodiment, the PV module 51 includes a first encapsulatingmaterial 15 protecting a front panel surface and a back panel surface ofthe photovoltaic panel 12 from the environment. For example, the firstencapsulating material 15 includes glass, foil, polymer, and/or alaminate of multiple materials. In another example, the front panelsurface is designed to face a light source (e.g., the sun) in order togenerate power. In another embodiment, the PV module 51 includes asecond encapsulating material 14 around a plurality of edge surfaces ofthe photovoltaic panel 12 for protecting the photovoltaic panel 12 fromthe environment. In one example, the second encapsulating material 14includes a polymer and/or other mixture of materials selected tominimize the damage to the photovoltaic panel 12. In yet anotherexample, the second encapsulating material 14 is placed above or belowand/or on the sides of each of the plurality of interconnect tabs 13. Inyet another embodiment, the first encapsulating material 15 and/or thesecond encapsulating material 14 substantially encloses the photovoltaicpanel 12 by, for example, covering all the surfaces of the photovoltaicpanel 12 except for the locations where the interconnect tabs 13 arelocated. In yet another embodiment, the first encapsulating material 15and/or the second encapsulating material 14 protects the photovoltaicpanel 12 from ambient conditions outside of the PV module 51, such asmoisture, abrasion, debris, and/or oxygen.

FIG. 5 is a simplified diagram showing a side view of a photovoltaicmodule 51 as part of the photovoltaic module interconnection system 100according to yet another embodiment of the present invention. Thisdiagram is merely an example, which should not unduly limit the scope ofthe claims. One of ordinary skill in the art would recognize manyvariations, alternatives, and modifications. As shown in FIG. 5, the PVmodule 51 includes a plurality of bus bars 42. In one example, theplurality of bus bars 42 are the plurality of bus bars 52. In anotherexample, each PV module 51 includes two bus bars 42 coupled to thepositive and negative ends of the array of photovoltaic cells includedin the PV module 51. In yet another example, the PV module 51 includesan interconnect tab 43 and an interconnect tab 44. In one embodiment,the interconnect tab 43 and the interconnect tab 44 are the plurality ofinterconnect tabs 53. In another embodiment, the interconnect tab 43and/or the interconnect tab 44 protrudes from the PV module 51 parallelto the bus bars 42. In yet another embodiment, the interconnect tab 43and/or the interconnect tab 44 protrudes from the PV module 51 at someangle relative to the respective bus bar 42. In yet another embodiment,interconnect tab 43 and/or interconnect tab 44 is an extension of therespective bus bar 42. In yet another example, the interconnect tab 43and/or the interconnect tab 44 is coated at least partially with anelectrically protective film.

FIG. 6 is a simplified diagram showing a side view of a photovoltaicmodule 51 as part of the photovoltaic module interconnection system 100according to yet another embodiment of the present invention. Thisdiagram is merely an example, which should not unduly limit the scope ofthe claims. One of ordinary skill in the art would recognize manyvariations, alternatives, and modifications. As shown in FIG. 6, the PVmodule 51 includes a photovoltaic panel 22 that includes active andconductive layers. For example, the photovoltaic panel 22 includes anymaterial such as silicon, cadmium telluride, CIGS, organics, and/orother photovoltaic active materials. In another example, thephotovoltaic module 51 includes a plurality of interconnect tabs 27. Inyet another example, the plurality of interconnect tabs 27 are theplurality of interconnect tabs 53. In yet another example, each of theplurality of interconnect tabs 27 are connected to a respective bus bar26 connected to the photovoltaic panel 12.

In one embodiment, each of the plurality of interconnect tabs 27 iscomposed of conductive tape and/or thin metal. In another embodiment,each of the plurality of interconnect tabs 27 protrudes from the side ofthe PV module 51. In yet another embodiment, each of the plurality ofinterconnect tabs 27 extends around the first encapsulating material 25to a front module surface or a back module surface of the PV module 51.For example, the front module surface is designed to face a light source(e.g., the sun) in order to generate power. In yet another embodiment,the PV module 51 provides physical support for each of the plurality ofinterconnect tabs 27 for subsequent interconnection of multiple PVmodules 51. In yet another embodiment, each of the plurality ofinterconnect tabs 27 is coated at least partially with an electricallyprotective film.

In yet another embodiment, the PV module 51 includes a firstencapsulating material 25 protecting a front panel surface and a backpanel surface of the photovoltaic panel 22 from the environment. Forexample, the first encapsulating material 25 includes glass, foil,polymer, and/or a laminate of multiple materials. In another example,the front panel surface is designed to face a light source (e.g., thesun) in order to generate power. In yet another example, the firstencapsulating material 25 is the first encapsulating material 15. In yetanother embodiment, the PV module 51 includes a second encapsulatingmaterial 24 around a plurality of edge surfaces of the photovoltaicpanel 22 for protecting the photovoltaic panel 212 from the environment.In one example, the second encapsulating material 24 includes a polymerand/or other mixture of materials selected to minimize the damage to thephotovoltaic panel 22. In yet another example, the second encapsulatingmaterial 24 is placed above or below and/or on the sides of each of theplurality of interconnect tabs 23. In yet another example, the secondencapsulating material 24 is the second encapsulating material 14. Inyet another embodiment, the first encapsulating material 25 and/or thesecond encapsulating material 24 substantially encloses the photovoltaicpanel 22 by, for example, covering all the surfaces of the photovoltaicpanel 22 except for the locations where the interconnect tabs 23 arelocated. In yet another embodiment, the first encapsulating material 25and/or the second encapsulating material 24 protects the photovoltaicpanel 22 from ambient conditions outside of the PV module 51, such asmoisture, abrasion, debris, and/or oxygen.

Returning to FIGS. 1 and 2, in another embodiment, interconnectionbetween a first PV module 51 and a second PV module is provided by themodule interconnector 57. In one example, the module interconnector 57includes an interconnection component 56 and an interconnectionprotector 54. In yet another embodiment, electrical interconnectionbetween the first PV module 51 and the second PV module 51 is providedby the interconnection component 56 coupled through a first connection55 (e.g., a first connection component) to a first interconnect tab 53on the first PV module 51 and coupled through a second connection 55(e.g., a second connection component) to a second interconnect tab 53 onthe second PV module 51. For example, the first connection 55 and/or thesecond connection 55 are crimped, soldered, welded, and/orultrasonically welded. In another example, the first connection 55 andthe second connection 55 are completed in the factory and/or completedat the installation site. In yet another example, the interconnectioncomponent 56 is made of the same type of metal as the first interconnecttab 53 and the second interconnect tab 53 to reduce the potential forcorrosion. In yet another embodiment, the first connection 55 and thesecond connection 55 are applied directly between the first interconnecttab 53 and the second interconnect tab 53 without interveninginterconnection component 56.

As shown in FIGS. 1 and 2, environmental protection for the electricalinterconnection is provided by interconnection protector 54. Forexample, the interconnection protector 54 also provides environmentalprotection for the interface of the interconnect tabs 53 and the PVmodules 51. In another example, the interconnection protector 54substantially encloses the interconnection component 56, the firstconnection 55, and the second connection 55, but, for example, providesaccess points for the first interconnect tab 53 and the secondinterconnect tab 54. In yet another example, the interconnectioncomponent 56, the first connection 55, and the second connection 55 arepotted (e.g., cemented) in place inside the interconnection protector 54using one or more potting materials. In yet another example, the one ormore potting materials fill a volume inside the interconnectionprotector 54 that is not occupied by the interconnection component 56,the first connection 55, and the second connection 55. In yet anotherexample, the one or more potting materials include a liquid encapsulant.In yet another example, the one or more potting materials include roomtemperature vulcanizing silicone and/or epoxy. In yet another example,the interconnection protector 54 provides physical strain relief for theinterconnection component 56, the first connection 55, the secondconnection 55, the first interconnect tab 53, and/or the secondinterconnect tab 53.

According to another embodiment, the interconnection protector 54 andthe interconnection component 56 provide strain relief to reduce strainduring thermal expansion of the PV modules 51 and/or the system thatholds the PV modules 51 in place. For example, interconnection component56 includes a thin sheet of metal with accordion folds (e.g., accordionbends) to allow lengthening and shortening, potted in soft polymerinside the interconnection protector 54. In another example, theinterconnection component 56 includes a flexible cable with slack toallow for expansion and contraction.

According to yet another embodiment, the interconnection protector 54also provides sufficient safety to prevent accidental contact toelectrical conductors (e.g., the interconnection component 56) at up toseveral thousand volts. For example, the interconnect tabs 53 areprovided with an electrically protective film to prevent electricalshock that is subsequently removed or pierced during assembly ofconnections 55.

According to yet another embodiment, the connections 55, theinterconnection component 56, and the interconnection protector 54 areinstalled on a group of modules 51 in a factory, for shipping apartially pre-assembled set of PV modules 51 to the installation site.For example, the module interconnector 57 allows a 180 degree bend topermit front-to-front and/or back-to-back folding of PV modules 51 in ashipping container. In another example, the folded PV modules 51 cansubsequently be rapidly and/or automatically unfolded at theinstallation site.

According to yet another embodiment, the interconnection protector 54 iscomposed of harder polymer on the outside for environmental protection,and softer polymer on the inside to allow for thermal expansion. Forexample, the interconnection protector 54 is filled with liquid and/orgrease. In another example, the softer material inside theinterconnection protector 54 is filled and/or cured in the factoryand/or at the installation site.

According to yet another embodiment, the interconnection protector 54allows the interconnection of the PV module 51 with a wiring harness atthe end of a string of PV modules 51.

According to yet another embodiment, the interconnection protector 54extends on a front module surface (e.g., the light side) of the PVmodule 51 but does not block the module active area from being exposedto sunlight. For example, the interconnection protector 54 extendsaround the back module surface (e.g., the dark side) of the PV module 51for added mechanical strength and/or environmental protection. Inanother example, the interconnection protector 54 provides a surfaceand/or a mating component for physically mounting the PV module 51 to aracking system with sufficient strength to resist forces such as gravityand wind loading.

In yet another embodiment, the interconnection protector 54 provides asemi-permanent interconnection. In one example, to replace the PV module51 at the installation site, it may be needed to cut the interconnectioncomponent 56 and re-join the cut interconnection component 56 withanother interconnection component 56 using solder, welding, ultrasonicwelding and/or crimping. In yet another example, the interconnectioncomponent 56 is provided with extra length to simplify the process ofcutting and re-joining. In one embodiment, the semi-permanent connectionprovided by the module interconnector 57 results in overall cost savingsin a large photovoltaic installation. In another embodiment, replacing amodule at the installation site is rare, so the cost savings byeliminating push-to-connect connectors is more than adequate to make upfor the extra effort required to cut and re-join the interconnectioncomponent 56.

According to yet another embodiment, without bulky connectors, PVmodules 51 can be packed closely together for volume-efficient shippingto the installation site. For example, shipping two 6-mm-thick typicalmodules, with 12 mm thick connectors, needs a minimum width of 24 mm ina packing container. In another example, shipping two 6-mm-thickmodules, with improved interconnections, needs a minimum width of 12 mmin a packing container, double the packing density of a typical module.In yet another example, pre-assembled sets of folded PV modules 51, asdescribed herein, are provided for faster installation at theinstallation site.

FIG. 7 is a simplified diagram showing a method for installingphotovoltaic modules 51 using the photovoltaic module interconnectionsystem 100 according to one embodiment of the present invention. Thisdiagram is merely an example, which should not unduly limit the scope ofthe claims. One of ordinary skill in the art would recognize manyvariations, alternatives, and modifications. As shown in FIG. 7, themethod 710 includes a process 700 for providing PV modules; a process701 for attaching interconnection tabs to PV modules; a process 702 forinterconnecting PV modules; a process 703 for attaching interconnectionprotectors; a process 704 for packing interconnected PV modules forshipping; and a process 705 for installing PV modules at theinstallation site. According to certain embodiments, the method 710 ofinstalling PV modules 51 using the photovoltaic module interconnectionsystem 100 can be performed using variations among the processes 700-705as would be recognized by one of ordinary skill in the art.

At the process 700, PV modules 51 according to one or more embodimentsof the present invention are provided. For example, PV modules 51 withthe plurality of bus bars 52 are provided. In another example, the PVmodules 51 include encapsulating materials (e.g., the firstencapsulating material 15 or 25 and/or the second encapsulating material14 or 24).

At the process 701, the plurality of interconnection tabs 53 areattached to the PV modules 51. In one example, each of the plurality ofinterconnection tabs are an extension of the respective bus bar 52. Inanother example, each of the plurality of interconnection tabs 53 are aseparate conductor connected to the end of the respective bus bar 52. Inyet another example, each of the plurality of interconnection tabs 53are attached either parallel to or at some other angle to the respectivebus 52. In yet another example, each of the plurality of interconnecttabs 53 is coated at least partially with an electrically protectivefilm.

At the process 702, the PV modules 51 are interconnected. In oneexample, a first interconnection tab 53 from a first PV module 51 iselectrically connected to a second interconnection tab 53 from a secondPV module 51 using a interconnection component 56 using connections 55.In another example, the first interconnection tab 53 from the first PVmodule 51 is electrically connected to the second interconnection tab 53from the second PV module 51 without intervening interconnectioncomponent 56.

At the process 703, the interconnection protector 54 is attached at eachinterconnection point. For example, the interconnection protector 54 isattached over the interconnection component 56 and/or the connections55. In another example, the interconnection protector 54 is potted inplace. In yet another example, the interconnection component 56, thefirst connection 55, and the second connection 55 are potted in placeinside the interconnection protector 54 using one or more pottingmaterials. In yet another example, the one or more potting materials areinjected into a volume inside the interconnection protector 54 that isnot occupied by the interconnection component 56, the first connection55, and the second connection 55. In yet another example, the one ormore potting materials include a liquid encapsulant. In yet anotherexample, the one or more potting materials subsequently cure to form aweatherproof layer. In yet another example, the one or more pottingmaterials include room temperature vulcanizing silicone and/or epoxy.

At the process 704, the interconnected PV modules 51 are packed forshipping. In one example, the PV modules 51 are folded front-to-frontand/or back-to-back at each interconnection point. In another example,the PV modules are packed in a shipping container.

At the process 705, the PV modules 51 are installed at the installationsite. In one example the interconnected PV modules 51 are unpacked fromthe shipping container. In another example, the interconnected PVmodules 51 are unfolded. In yet another example, the interconnected PVmodules 51 are mounted to a rail and/or some other type of mountingsystem at their final installation location.

As discussed above and further emphasized here, FIG. 7 is merely anexample, which should not unduly limit the scope of the claims. One ofordinary skill in the art would recognize many variations, alternatives,and modifications. For example, a process for shipping, to aninstallation site, at least the interconnected and packed firstphotovoltaic module 51 and second photovoltaic module 51 occurs betweenthe process 704 for packing interconnected PV modules for shipping andthe process 705 for installing PV modules at the installation site. Inanother example, a process for unpacking the interconnected and packedfirst photovoltaic module 51 and second photovoltaic module 51 occursbetween the process 704 for packing interconnected PV modules forshipping and the process 705 for installing PV modules at theinstallation site.

FIG. 8 is a simplified diagram showing a method for installingphotovoltaic modules 51 using the photovoltaic module interconnectionsystem 100 according to another embodiment of the present invention.This diagram is merely an example, which should not unduly limit thescope of the claims. One of ordinary skill in the art would recognizemany variations, alternatives, and modifications. As shown in FIG. 8,the method 810 includes a process 800 for providing PV modules; aprocess 801 for installing PV modules; a process 802 for interconnectingPV modules; and a process 803 for attaching interconnection protectors.According to certain embodiments, the method 810 of installing PVmodules 51 using the photovoltaic module interconnection system 100 canbe performed using variations among the processes 800-803 as would berecognized by one of ordinary skill in the art.

At the process 800, PV modules 51 with the plurality of interconnectiontabs 53 according to one or more embodiments of the present inventionare provided. For example, PV modules 51 with the plurality of bus bars52 are provided. In another example, the PV modules 51 includeencapsulating materials (e.g., the first encapsulating material 15 or 25and/or the second encapsulating material 14 or 24). In yet anotherexample, the plurality of interconnection tabs 53 are attached to the PVmodules 51. In yet another example, each of the plurality ofinterconnection tabs are an extension of the respective bus bar 52. Inyet another example, each of the plurality of interconnection tabs 53are a separate conductor connected to the end of the respective bus bar52. In yet another example, each of the plurality of interconnectiontabs 53 are attached either parallel to or at some other angle to therespective bus 52. In yet another example, each of the plurality ofinterconnect tabs 53 is coated at least partially with an electricallyprotective film. In yet another example, the electrically protectivefilm prevents electrical shock during handling of the PV modules 51.

At the process 801, the PV modules 51 are installed at the installationsite. In one example the interconnected PV modules 51 are unpacked fromshipping containers. In another example, the interconnected PV modules51 are mounted to a rail and/or some other type of mounting system attheir final installation location.

At the process 802, the PV modules 51 are interconnected. In oneexample, a first interconnection tab 53 from a first PV module 51 iselectrically connected to a second interconnection tab 53 from a secondPV module 51 using an interconnection component 56 and connections 55.In another example, the first interconnection tab 53 from the first PVmodule 51 is electrically connected to the second interconnection tab 53from the second PV module 51 without the intervening interconnectioncomponent 56. In yet another example, the electrically protective filmon the first interconnection tab 53 and the electrically protective filmon the second interconnection tab 53 is pierced and/or removed.

At the process 803, the interconnection protector 54 is attached at eachinterconnection point. For example, the interconnection protector 54 isattached over the interconnection component 56 and/or the connections55. In another example, the interconnection protector 54 is potted inplace. In yet another example, the interconnection component 56, thefirst connection 55, and the second connection 55 are potted in placeinside the interconnection protector 54 using one or more pottingmaterials. In yet another example, the one or more potting materials areinjected to a volume inside the interconnection protector 54 that is notoccupied by the interconnection component 56, the first connection 55,and the second connection 55. In yet another example, the one or morepotting materials include a liquid encapsulant. In yet another example,the one or more potting materials subsequently cure to form aweatherproof layer. In yet another example, the one or more pottingmaterials include room temperature vulcanizing silicone and/or epoxy.

As discussed above and further emphasized here, FIG. 8 is merely anexample, which should not unduly limit the scope of the claims. One ofordinary skill in the art would recognize many variations, alternatives,and modifications. For example, a process for packing, for shipping, atleast the first photovoltaic module 51 and second photovoltaic module 51occurs between the process 800 for providing PV modules and the process801 for installing PV modules. In another example, a process forshipping, to an installation site, at least the first photovoltaicmodule 51 and second photovoltaic module 51 occurs between the process800 for providing PV modules and the process 801 for installing PVmodules. In yet another example, a process for unpacking the packedfirst photovoltaic module 51 and second photovoltaic module 51 occursbetween the process 800 for providing PV modules and the process 801 forinstalling PV modules.

According to at least one embodiment, a system for interconnectingphotovoltaic modules includes a first photovoltaic module and a secondphotovoltaic module. The first photovoltaic module includes a first busbar and a first interconnect tab connected to the first bus bar. Thesecond photovoltaic module includes a second bus bar and a secondinterconnect tab connected to the second bus bar. The system forinterconnecting photovoltaic modules additionally includes a moduleinterconnector configured to interconnect the first photovoltaic moduleand the second photovoltaic module. The module interconnector includesan interconnection component and an interconnection protector.Additionally, the system for interconnecting photovoltaic modulesincludes a first connection component connecting the interconnectioncomponent to the first interconnect tab of the first photovoltaic moduleand a second connection component connecting the interconnectioncomponent to the second interconnect tab of the second photovoltaicmodule. The interconnection protector substantially encloses theinterconnection component, the first connection component, and thesecond connection component. For example, the system for interconnectingphotovoltaic modules is implemented according to at least FIG. 1, FIG.2, FIG. 3, FIG. 4, FIG. 5, and/or FIG. 6.

In another example, the first photovoltaic module includes one selectedfrom a group consisting of silicon, cadmium telluride, CIGS, andorganics. In yet another example, the first photovoltaic module furtherincludes an array of photovoltaic cells, the array of photovoltaic cellsincludes a positive end and a negative end and the first bus bar iscoupled to either the positive end or the negative end. In yet anotherexample, the first interconnect tab protrudes from a side of the firstphotovoltaic module. In yet another example, the first interconnect tabis an extension of the first bus bar. In yet another example, the firstinterconnect tab is a separate conductor from the first bus bar. In yetanother example, the first interconnect tab protrudes from the side ofthe first photovoltaic module in parallel with the first bus bar. In yetanother example, the first interconnect tab protrudes from the side ofthe first photovoltaic module at an angle to the first bus bar. In yetanother example, the first interconnect tab is coated at least partiallyby a protective film.

In yet another example, the first photovoltaic module further includes aphotovoltaic panel including a front panel surface, a back panelsurface, and a plurality of edge surfaces. And the first photovoltaicmodule further includes a first encapsulating material for protectingthe front panel surface of the photovoltaic panel and the back panelsurface of the photovoltaic panel and a second encapsulating materialfor protecting the plurality of edge surfaces of the photovoltaic panel.Additionally, the first encapsulating material and the secondencapsulating material substantially enclose the photovoltaic panel. Inyet another example, the second encapsulating material is placed above,below, and to the sides of the first interconnect tab. In yet anotherexample, the first photovoltaic module further includes a front modulesurface and a back module surface and the first interconnect tab extendsaround the first encapsulating material to the front module surface orthe back module surface of the first photovoltaic module. In yet anotherexample, the interconnection component is potted inside the protectorusing a polymer. In yet another example, the interconnection componentincludes a flexible cable. In yet another example, the interconnectioncomponent includes a thin sheet of metal including accordion folds. Inyet another example, the first connection is formed by at least oneselected from a group consisting of crimping, soldering, welding, andultrasonic welding. In yet another example, the first connectioncomponent, the second connection component, and the interconnectioncomponent include the same metal. In yet another example, theinterconnection protector provides electrical and environmentalprotection to the interconnection component, the first connectioncomponent, and the second connection component.

According to another embodiment, a method for installing photovoltaicmodules includes providing a first photovoltaic module that includes afirst bus bar, providing a second photovoltaic module that includes asecond bus bar, attaching a first interconnect tab to the first bus bar,and attaching a second interconnect tab to the second bus bar. Themethod for installing photovoltaic modules further includesinterconnecting the first photovoltaic module and the secondphotovoltaic module by connecting the first interconnect tab to aninterconnection component with a first connection component and byconnecting the second interconnect tab to the interconnection componentwith a second connection component. The method for installingphotovoltaic modules additionally includes enclosing substantially theinterconnection component, the first connection component, and thesecond connection component by an interconnection protector. The methodfor installing photovoltaic modules additionally includes packing, forshipping, at least the first photovoltaic module and the secondphotovoltaic module, the first photovoltaic module and the secondphotovoltaic module being interconnected to each other, shipping, to aninstallation site, at least the packed first photovoltaic module andsecond photovoltaic module, the first photovoltaic module and the secondphotovoltaic module being interconnected to each other, and installing,at the installation site, at least the first photovoltaic module and thesecond photovoltaic module. For example, the method is implementedaccording to at least FIG. 7.

In another example, the first photovoltaic module includes one selectedfrom a group consisting of silicon, cadmium telluride, CIGS, andorganics. In yet another example, the process for packing, for shipping,at least the first photovoltaic module and the second photovoltaicmodule includes stacking the first photovoltaic module and the secondphotovoltaic module either front-to-back or back-to-front by folding theinterconnection component and the interconnection protector.

According to yet another embodiment, a method for installingphotovoltaic modules includes providing a first photovoltaic module thatincludes a first bus bar and a first interconnect tab connected to thefirst bus bar and providing a second photovoltaic module that includes asecond bus bar and a second interconnect tab connected to the second busbar. The method for installing photovoltaic modules further includescoating the first interconnect tab at least partially with a firstprotective film and coating the second interconnect tab at leastpartially with a second protective film. The method for installingphotovoltaic modules additionally includes packing, for shipping, atleast the first photovoltaic module and the second photovoltaic module,shipping, to an installation site, at least the packed firstphotovoltaic module and second photovoltaic module, and installing, atthe installation site, at least the first photovoltaic module and thesecond photovoltaic module. The method for installing photovoltaicmodules additionally includes interconnecting, at the installation site,the installed first photovoltaic module and the installed secondphotovoltaic module by connecting the first interconnect tab to aninterconnection component with a first connection component and byconnecting the second interconnect tab to the interconnection componentwith a second connection component. The method for installingphotovoltaic modules additionally includes enclosing substantially theinterconnection component, the first connection component, and thesecond connection component with an interconnection protector. Forexample, the method is implemented according to at least FIG. 8.

In another example, the first photovoltaic module includes one selectedfrom a group consisting of silicon, cadmium telluride, CIGS, andorganics. In yet another example, the process for interconnecting, atthe installation site, the installed first photovoltaic module and theinstalled second photovoltaic module includes piercing the firstprotective film and piercing the second protective film. In yet anotherexample, the process for interconnecting, at the installation site, theinstalled first photovoltaic module and the installed secondphotovoltaic module removing the first protective film and removing thesecond protective film.

Although specific embodiments of the present invention have beendescribed, it will be understood by those of skill in the art that thereare other embodiments that are equivalent to the described embodiments.For example, various embodiments and/or examples of the presentinvention can be combined. Accordingly, it is to be understood that theinvention is not to be limited by the specific illustrated embodiments,but only by the scope of the appended claims.

What is claimed is:
 1. A system for interconnecting photovoltaicmodules, comprising: a first photovoltaic module including a first busbar and a first interconnect tab connected to the first bus bar; asecond photovoltaic module including a second bus bar and a secondinterconnect tab connected to the second bus bar; a moduleinterconnector configured to interconnect the first photovoltaic moduleand the second photovoltaic module, the module interconnector includingan interconnection component and an interconnection protector; a firstconnection component connecting the interconnection component to thefirst interconnect tab of the first photovoltaic module; and a secondconnection component connecting the interconnection component to thesecond interconnect tab of the second photovoltaic module; wherein theinterconnection protector substantially encloses the interconnectioncomponent, the first connection component, and the second connectioncomponent.
 2. The system of claim 1 wherein the first photovoltaicmodule includes one selected from a group consisting of silicon, cadmiumtelluride, CIGS, and organics.
 3. The system of claim 1 wherein: thefirst photovoltaic module further includes an array of photovoltaiccells, the array of photovoltaic cells including a positive end and anegative end; and the first bus bar is coupled to either the positiveend or the negative end.
 4. The system of claim 1 wherein the firstinterconnect tab protrudes from a side of the first photovoltaic module.5. The system of claim 4 wherein the first interconnect tab is anextension of the first bus bar.
 6. The system of claim 4 wherein thefirst interconnect tab is a separate conductor from the first bus bar.7. The system of claim 4 wherein the first interconnect tab protrudesfrom the side of the first photovoltaic module in parallel with thefirst bus bar.
 8. The system of claim 4 wherein the first interconnecttab protrudes from the side of the first photovoltaic module at an angleto the first bus bar.
 9. The system of claim 1 wherein the firstinterconnect tab is coated at least partially by a protective film. 10.The system of claim 1 wherein the first photovoltaic module furtherincludes: a photovoltaic panel including a front panel surface, a backpanel surface, and a plurality of edge surfaces; a first encapsulatingmaterial for protecting the front panel surface of the photovoltaicpanel and the back panel surface of the photovoltaic panel; and a secondencapsulating material for protecting the plurality of edge surfaces ofthe photovoltaic panel; wherein the first encapsulating material and thesecond encapsulating material substantially enclose the photovoltaicpanel.
 11. The system of claim 10 wherein the second encapsulatingmaterial is placed above, below, and to the sides of the firstinterconnect tab.
 12. The system of claim 10 wherein: the firstphotovoltaic module further includes a front module surface and a backmodule surface; and the first interconnect tab extends around the firstencapsulating material to the front module surface or the back modulesurface of the first photovoltaic module.
 13. The system of claim 1wherein the interconnection component is potted inside the protectorusing a polymer.
 14. The system of claim 1 wherein the interconnectioncomponent includes a flexible cable.
 15. The system of claim 1 whereinthe interconnection component includes a thin sheet of metal includingaccordion folds.
 16. The system of claim 1 wherein the first connectionis formed by at least one selected from a group consisting of crimping,soldering, welding, and ultrasonic welding.
 17. The system of claim 1wherein the first connection component, the second connection component,and the interconnection component include the same metal.
 18. The systemof claim 1 wherein the interconnection protector provides electrical andenvironmental protection to the interconnection component, the firstconnection component, and the second connection component.
 19. A methodfor installing photovoltaic modules, comprising: providing a firstphotovoltaic module including a first bus bar; providing a secondphotovoltaic module including a second bus bar; attaching a firstinterconnect tab to the first bus bar; attaching a second interconnecttab to the second bus bar; interconnecting the first photovoltaic moduleand the second photovoltaic module by connecting the first interconnecttab to an interconnection component with a first connection componentand by connecting the second interconnect tab to the interconnectioncomponent with a second connection component; enclosing substantiallythe interconnection component, the first connection component, and thesecond connection component by an interconnection protector; packing,for shipping, at least the first photovoltaic module and the secondphotovoltaic module, the first photovoltaic module and the secondphotovoltaic module being interconnected to each other; shipping, to aninstallation site, at least the packed first photovoltaic module andsecond photovoltaic module, the first photovoltaic module and the secondphotovoltaic module being interconnected to each other; and installing,at the installation site, at least the first photovoltaic module and thesecond photovoltaic module.
 20. The method of claim 19 wherein the firstphotovoltaic module includes one selected from a group consisting ofsilicon, cadmium telluride, CIGS, and organics.
 21. The method of claim19 wherein the process for packing, for shipping, at least the firstphotovoltaic module and the second photovoltaic module includes stackingthe first photovoltaic module and the second photovoltaic module eitherfront-to-back or back-to-front by folding the interconnection componentand the interconnection protector.
 22. A method for installingphotovoltaic modules, comprising: providing a first photovoltaic moduleincluding a first bus bar and a first interconnect tab connected to thefirst bus bar; providing a second photovoltaic module including a secondbus bar and a second interconnect tab connected to the second bus bar;coating the first interconnect tab at least partially with a firstprotective film; coating the second interconnect tab at least partiallywith a second protective film; packing, for shipping, at least the firstphotovoltaic module and the second photovoltaic module; shipping, to aninstallation site, at least the packed first photovoltaic module andsecond photovoltaic module; and installing, at the installation site, atleast the first photovoltaic module and the second photovoltaic module;interconnecting, at the installation site, the installed firstphotovoltaic module and the installed second photovoltaic module byconnecting the first interconnect tab to an interconnection componentwith a first connection component and by connecting the secondinterconnect tab to the interconnection component with a secondconnection component; and enclosing substantially the interconnectioncomponent, the first connection component, and the second connectioncomponent with an interconnection protector.
 23. The method of claim 22wherein the first photovoltaic module includes one selected from a groupconsisting of silicon, cadmium telluride, CIGS, and organics.
 24. Themethod of claim 22 wherein the process for interconnecting, at theinstallation site, the installed first photovoltaic module and theinstalled second photovoltaic module includes piercing the firstprotective film and piercing the second protective film.
 25. The methodof claim 22 wherein the process for interconnecting, at the installationsite, the installed first photovoltaic module and the installed secondphotovoltaic module removing the first protective film and removing thesecond protective film.